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Caterpillar GP25ZN Lift Truck Service Manuals – PDF DOWNLOAD
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Caterpillar GP25ZN Lift Truck Service Manuals – PDF DOWNLOAD
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Description
Caterpillar GP25ZN Lift Truck Service Manuals – PDF DOWNLOAD
DESCRIPTION:
Caterpillar GP25ZN Lift Truck Service Manuals – PDF DOWNLOAD
FOREWORD:
This service manual is a guide for servicing Cat lift trucks. The long productive life of your lift trucks(s) depends on regular and proper servicing consistent with what you will learn by reading this service manual.
- Read the respective sections of this manual carefully and familiarize yourself with all of the components before attempting to start a test, repair, or rebuild the lift trucks. The descriptions, illustrations, and specifications contained in this manual are for lift trucks with serial numbers in effect at the time of printing.
- Cat Lift Trucks reserves the right to change specifications or designs without notice and without incurring obligations. For your convenience the instructions are grouped by systems as an easy reference.
For engine servicing, please refer to the applicable engine service manual.
K15, K21, or K25 Gasoline engine
S4Q2 or S4S Diesel engine
SAFETY PRECAUTIONS :
- Be sure to read this service manual and understand the contents before proceeding with the work. Improper truck operation is dangerous and could result in injury or death. Be sure to familiarize yourself with the systems and components described herein before proceeding with removal or disassembly work.
- For heavyweight components, BE SURE to check the weight of each component beforehand by referring to this service manual. Also, for safety, use proper lifting equipment for removal/ installation work. Following is a list of basic precautions that should always be observed.
(1) Read and understand all warning plates and decals on the truck before proceeding with operation, lubrication, or repair work.
(2) Always wear safety glasses and protective shoes when working around trucks. Be sure to wear safety glasses to prevent any type of metal from getting into your eyes when using a hammer or sledge. Use welders gloves, hood/goggles, apron, and other protective clothing appropriate to the welding operation. Do not wear loose clothing or accessories that can be caught in moving parts. Do not wear rings when you work.
(3) Do not work on any truck that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the truck before proceeding with the work.
(4) Lower the forks or other implements to the ground before performing any work on the truck. If this cannot be done, make sure the forks or other implements are blocked correctly to prevent them from dropping unexpectedly.
(5) Use steps and assist grips (if equipped) when you mount or dismount the truck. Clean the steps, hand rails, and floor of operator seat beforehand. Always face the truck when using steps, ladders, and walkways. If you cannot use the designed access system, use ladders, scaffolds, or work platforms to ensure the safety at the workplace.
(6) To avoid back injury, use a hoist when lifting components which weigh 23 kg (51 lb) or more. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Make sure the load is well balanced prior to lifting. (7) To prevent burns, DO NOT touch hot sections of the truck immediately after stopping the truck.
(8) Remove covers carefully. When removing the last two bolts or nuts, loosen gradually to release spring force or pressure.
(9) Be careful when removing filler caps, breathers and plugs on the truck. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. Use extreme care immediately after stopping.
(10) Use well maintained tools in a proper way.
TABLE OF CONTENTS:
Caterpillar GP25ZN Lift Truck Service Manuals – PDF DOWNLOAD
99719-3F110-00_FOREWORD..................................... 1 99719-3F110-00_FOREWORD................................. 5 99719-3F110-01_GENERAL_INFORMATION.......................... 25 99719-3F110-01_GENERAL INFORMATION...................... 25 99719-3F110-02_COOLING_SYSTEM............................... 33 99719-3F110-02_COOLING SYSTEM........................... 33 99719-3F110-03_ELECTRICAL_SYSTEM............................ 39 99719-3F110-03_ELECTRICAL SYSTEM........................ 39 99719-3F110-04_CONTROLLER................................... 107 99719-3F110-04_CONTROLLER............................... 107 99719-3F110-04_CONTROLLERS.................................. 179 99719-3F110-05_POWER_TRAIN.................................. 251 99719-3F110-05_POWER TRAIN.............................. 251 99719-3F110-06_CLUTCHES..................................... 265 99719-3F110-06_CLUTCHES................................. 265 99719-3F110-07_MANUAL_TRANSMISION........................... 303 99719-3F110-07_MANUAL TRANSMISION....................... 303 99719-3F110-07_MANUAL_TRANSMISSION.......................... 331 99719-3F110-08_POWERSHIFT_TRANSMISSION...................... 359 99719-3F110-08_POWERSHIFT TRANSMISSION.................. 359 99719-3F110-09_FRONT_AXLE_AND_REDUCTION_DIFFERENTIAL........ 451 99719-3F110-09_FRONT AXLE AND REDUCTION DIFFERENTIAL.... 451 99719-3F110-10_REAR_AXLE.................................... 479 99719-3F110-10_REAR AXLE................................ 479 99719-3F110-11_BRAKE_SYSTEM................................. 495 99719-3F110-11_BRAKE SYSTEM............................. 495 99719-3F110-12_STEERING_SYSTEM.............................. 519 99719-3F110-12_STEERING SYSTEM.......................... 519 99719-3F110-13_HYDRAULIC_SYSTEM............................. 541 99719-3F110-13_HYDRAULIC SYSTEM......................... 541 99719-3F110-14_MAST_AND_FORKS............................... 609 99719-3F110-14_MAST AND FORKS........................... 609 99719-3F110-15_SERVICE_DATA................................. 705 99719-3F110-15_SERVICE DATA............................. 705 99719-3F120-01.............................................. 731 99719-3F120-03.............................................. 739 99719-3F120-03.......................................... 739 99719-3F120s............................................ 807 99719-3F120s_01..................................... 807 99719-3F120s_02..................................... 808 99719-3F120s_03..................................... 809 99719-3F120s_04..................................... 810 99719-3F120-15.............................................. 811 99719-3F120T-00............................................. 839 99719-6W110-00_FOREWORD..................................... 862 99719-6W110-01_GENERAL...................................... 868 99719-6W110-02_ELECTRICAL_SYSTEM............................ 872 99719-6W110-02A_WIRING_DIAGRAM.............................. 882 99719-6W110s_Gasoline................................... 882 99719-6W110s_Diesel..................................... 883 99719-6W110-03_CONTROLLER................................... 884 99719-6W110-04_POWER_TRAIN.................................. 900 99719-6W110-05_TORQUE_CONVERTER_DRIVE_TRANSMISSION.......... 920 99719-6W110-06_FRONT_AXLE_AND_REDUCTION_DIFFERENTIAL........ 924 99719-6W110-07_BRAKE_SYSTEM................................. 950 99719-6W110-08_SERVICE_DATA................................. 978 99719-35120-00_FOREWORD..................................... 986 99719-35120-00_FOREWORD................................. 987 99719-35120-01_GENERAL_INFORMATION.......................... 994 99719-35120-01_GENERAL INFORMATION...................... 994 99719-35120-02_COOLING_SYSTEM...............................1004 99719-35120-02_COOLING SYSTEM...........................1004 99719-35120-03_ELECTRICAL_SYSTEM............................1011 99719-35120-03_ELECTRICAL SYSTEM........................1011 99719-35120-04_CONTROLLERS..................................1082 99719-35120-04_CONTROLLERS..............................1082 99719-35120-05_POWER_TRAIN..................................1140 99719-35120-05_POWER TRAIN..............................1140 99719-35120-06_CLUTCHES.....................................1157 99719-35120-06_CLUTCHES.................................1157 99719-35120-07_MANUAL_TRANSMISION...........................1194 99719-35120-07_MANUAL TRANSMISION.......................1194 99719-35120-08_POWERSHIFT_TRANSMISSION......................1218 99719-35120-08_POWERSHIFT TRANSMISSION..................1218 99719-35120-09_FRONT_AXLE_AND_REDUCTION_DIFFERENTIAL........1263 99719-35120-09_FRONT AXLE AND REDUCTION DIFFERENTIAL....1263 99719-35120-10_REAR_AXLE....................................1291 99719-35120-10_REAR AXLE................................1291 99719-35120-11_BRAKE_SYSTEM.................................1302 99719-35120-11_BRAKE SYSTEM.............................1302 99719-35120-12_STEERING_SYSTEM..............................1325 99719-35120-12_STEERING SYSTEM..........................1325 99719-35120-13_HYDRAULIC_SYSTEM.............................1342 99719-35120-13_HYDRAULIC SYSTEM.........................1342 99719-35120-14_MAST_AND_FORKS...............................1429 99719-35120-14_MAST AND FORKS...........................1429 99719-35120-15_SERVICE_DATA.................................1520 99719-35120-15_SERVICE DATA.............................1520 99719-38110-00_FOREWORD.....................................1540 99719-38110-01_GENERAL_INFORMATION..........................1551 99719-38110-02_COOLING_SYSTEM...............................1561 99719-38110-03_ELECTRIC_SYSTEM..............................1567 99719-38110-04_CONTROLLERS..................................1622 99719-38110-05_POWER_TRAIN..................................1702 99719-38110-06_CLUTCHES.....................................1718 99719-38110-07_MANUAL_TRANSMISSION..........................1756 99719-38110-08_POWERSHIFT_TRANSMISSION......................1782 99719-38110-09_FRONT_AXLE_AND_REDUCTION_DIFFERENTIAL........1872 99719-38110-10_REAR_AXLE....................................1900 99719-38110-11_BRAKE_SYSTEM.................................1916 99719-38110-12_STEERING_SYSTEM..............................1940 99719-38110-13_HYDRAULIC_SYSTEM.............................1960 99719-38110-14_MAST_AND_FORKS...............................2048 99719-38110-15_SERVICE_DATA.................................2138 99719-38210-00_FOREWORD.....................................2209 99719-38210-00_FOREWORD.................................2210 99719-38210-01_GENERAL_INFORMATION..........................2230 99719-38210-01_GENERAL INFORMATION......................2230 99719-38210-02_COOLING_SYSTEM...............................2238 99719-38210-02_COOLING SYSTEM...........................2238 99719-38210-03_ELECTRICAL_SYSTEM............................2243 99719-38210-03_ELECTRICAL SYSTEM........................2243 99719-38210-04_CONTROLLER...................................2315 99719-38210-04_CONTROLLER...............................2315 99719-38210-05_POWER_TRAIN..................................2386 99719-38210-05_POWER TRAIN..............................2386 99719-38210-06_CLUTCHES.....................................2400 99719-38210-06_CLUTCHES.................................2400 99719-38210-07_MANUAL_TRANSMISION...........................2438 99719-38210-07_MANUAL TRANSMISION.......................2438 99719-38210-08_POWERSHIFT_TRANSMISSION......................2465 99719-38210-08_POWERSHIFT TRANSMISSION..................2465 99719-38210-09_FRONT_AXLE_AND_REDUCTION_DIFFERENTIAL........2557 99719-38210-09_FRONT AXLE AND REDUCTION DIFFERENTIAL....2557 99719-38210-10_REAR_AXLE....................................2585 99719-38210-10_REAR AXLE................................2585 99719-38210-11_BRAKE_SYSTEM.................................2601 99719-38210-11_BRAKE SYSTEM.............................2601 99719-38210-12_STEERING_SYSTEM..............................2624 99719-38210-12_STEERING SYSTEM..........................2624 99719-38210-13_HYDRAULIC_SYSTEM.............................2645 99719-38210-13_HYDRAULIC SYSTEM.........................2645 99719-38210-14_MAST_AND_FORKS...............................2712 99719-38210-14_MAST AND FORKS...........................2712 99719-38210-15_SERVICE_DATA.................................2808 99719-38210-15_SERVICE DATA.............................2808 99739-351T0-00..............................................2833 99739-351T0-01..............................................2838 99739-351T0-02..............................................2839 99739-351T0-03..............................................2841 99739-351T0-04..............................................2844 99739-351T0-05..............................................2856 99739-351T0-06..............................................2865 99739-351T0-07..............................................2866 99739-351T0-08..............................................2868 99789-85110-00..............................................2870 99789-85110-01..............................................2875 99789-85110-02..............................................2902 99789-85110-03..............................................2914 99789-85110-04..............................................2934 99789-85110-05..............................................2983 99789-85110-06..............................................3063 99789-85110-07..............................................3072 99789-85110-08..............................................3097 99789-87100-00..............................................3115 99789-87100-01..............................................3120 99789-87100-02..............................................3147 99789-87100-03..............................................3159 99789-87100-04..............................................3179 99789-87100-05..............................................3230 99789-87100-06..............................................3287 99789-87100-07..............................................3296 99789-87100-08..............................................3324
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CATERPILLAR GP25ZN LIFT TRUCK SERVICE MANUALS – PDF DOWNLOAD:
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
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